Automated prescription and/or literature bagger system and method optionally integrated with automated dispensing system and/or automated labeling and packaging system

ABSTRACT

A system and method places a printed label on a bag. A first plurality of rollers can feed one or more bags, and a second plurality of rollers can feed one or more labels. A tamp pad can place the label on the bag.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/634,991, filed Aug. 6, 2003, (now U.S. Pat. No. 7,010,899, IssuedMar. 14, 2006, which claims priority to, and is a continuation-in-partof U.S. application Ser. No. 10/215,249, filed Aug. 9, 2002 now U.S.Pat. No. 6,892,512, which claims priority from U.S. provisionalapplication Ser. No. 60/401,340 filed Aug. 7, 2002, each incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention generally relates to systems and methods forplacing one or more literature packages and/or one or morepharmaceutical containers, that include medications, into a container tofacilitate delivery of the literature package(s) and/or pharmaceuticalcontainer(s) to a recipient.

BACKGROUND OF THE INVENTION

In mail service pharmacies and large retail pharmacies, prescriptiondrugs are dispensed in a high volume. For such services, automatic pilldispensing systems can be used to dispense prescription drugs and labelpill containers, which can then be provided to a patient for whom theprescription was written.

A known automatic pill dispensing system 100 is described in U.S. Pat.No. 5,771,657, which is incorporated herein by reference. In the patent,as shown in FIG. 1A, orders (e.g., orders to fill prescriptions) arereceived by a host computer 9 which forwards the orders to a distributedcomputer system that can include a central computer called PharmacyAutomation Controller 10 (PAC). PAC 10 maintains an order file of theinformation about each prescription to be filled that can includeinformation needed to fill each prescription. The order file can, forexample, be used to prepare a prescription label for eachbottle/container (hereinafter bottle). The order file can also be usedto facilitate printing literature that can be placed in a shippingcontainer with the bottle(s). PAC 10 can also update the order file tomaintain a record of the current status of each prescription beingfilled as it progresses through the automated system.

PAC 10 can control a set of Print, Apply and Load (PAL) stations 14which print prescription bottle labels, apply the labels to bottles, andload the labeled bottles onto bottle carriers that preferably receivethe bottles in scheduled locations. PAC 10 can also control a carrierconveyer system 21 that carries the bottle carriers to different partsof system 100, and one or more automatic drug dispensing machines 23that dispense tablets and/or capsules into the bottles in the bottlecarriers as they are carried by conveyer system 21. In addition, PAC 10controls bottle cappers 25 that apply caps to the bottles, and OCPstations 29 that unload bottles from the carriers and place them inshipping containers corresponding to a patient order. Further, PAC 10can control literature printers 31 which print literature, for eachprescription order, that can be enclosed in an envelope. Finally, PAC 10can utilize bar code data that identifies the prescription order. Thebar code can show through a window in the envelope. Envelopes can beplaced on a literature conveyer 34 which carries the envelopes from theliterature printers 31 to the OCP stations 29.

Conveyer system 21 carries the bottles in the carriers from PAL stations14 through the automatic drug dispensing machines 23 to bottle cappers25, and then from bottle cappers to OCP stations 29. Conveyer system 21also carries empty carriers back to PAL stations 14. From bottle cappers25, conveyers 56 feed the carriers onto an endless conveyer loop 71which transports, for example, four carriers of a rank to one of, say,six OCP stations 29. Other numbers of OCP stations 29 can also beutilized. OCP stations 29 each also have a literature dispensingmechanism, which inserts the printed literature into each shippingcontainer with the filled and capped prescription bottles.

As shown in FIG. 1B, bottles to be automatically filled with theprescription drugs are introduced to the automated system by hoppers 37,which receive the bottles in bulk form and automatically feed thebottles to unscramblers 39. One of the hoppers 37 and one of theunscramblers 39 will be for large bottles (e.g., 160 cc), and theremaining hoppers and unscramblers will be for small bottles (e.g., 110cc). The small bottle size can preferably accommodate a majority of theautomatically filled prescriptions. In the unscramblers, the bottles aresingulated and oriented so that the bottle opening first faces downward.The bottles are then righted and directed to PAL stations 14 on bottleconveyers 41 and 43, one for large bottles and one for small bottles.

Conveyers 45, under control by PAC 10, carry the bottle carriers fromthe four PAL stations 14 to carrier buffers at the entrances of the fourautomatic drug dispensing machines 23 in which the tablets or capsulesof the prescriptions are automatically dispensed into the prescriptionbottles under the control of PAC 10. Because of the organizationprovided by the carriers, the bottles are arranged into four columnsapproaching each automatic dispensing machine 23. Since there are fourautomatic dispensing machines 23, 16 parallel prescription bottlecolumns can approach the dispensing machines. In this embodiment, thefour automatic drug dispensing machines each have 384 drug dispensersarranged four columns wide and 96 rows deep to provide a total of 1,536pill dispensers. The automatic drug dispensing machines are similar tothose described in the U.S. Pat. No. 5,660,305, which is herebyincorporated by reference. Each dispensing lane is divided into 32buffer assemblies, each containing twelve drug dispensers oriented sixon each side of a conveyer within the dispensing machine.

The carrier will be released by PAL station 14 onto a conveyer 45 whichcarries the carrier loaded with the labeled empty prescription bottlesto an automatic dispensing machine 23, of which there are four, one foreach PAL station 14. When a carrier moves out of the last row positionin a dispensing machine, all of the prescription bottles in that bottlecarrier should be filled and a conveyer 56 transports the prescriptionbottles now filled with the prescriptions to a bottle capper 25.

Bottle quality assurance area 109 has several stations at whichpharmacists can scan the bar code on the bottles and visually inspectthe contents of the bottles. The scan of the bottle bar code will bringup a display on the pharmacist's terminal which preferably includes allthe information regarding the particular prescription and order. Suchinformation can include, for example, the drug name, and instructionswhich identify the reason for the verification. All of the bottles thatpass this inspection can be inserted or reinserted by the pharmacist ona bottle stream conveyer 111 to send the inspected bottles to the BSPstation 112. Conveyer 108 leads to a star wheel diverter mechanism 114which, optionally under the control of a controller for BSP station 112,deposits the bottle in a bottle stream conveyer 116 leading to thebottle quality assurance area 109 or into a bottle stream conveyer 118leading to BSP station 112.

If the literature pack is on conveyer 34, but because of failure of thebar code reader (not shown) or the literature sorting mechanism (notshown), does not get diverted at BSP station 112, conveyer 34 will carrythe literature package to package quality assurance area 96 where theliterature pack can be manually added to the package. If, because of amalfunction, a literature envelope is not deflected by a deflector 89(FIG. 1C), because of, for example, an improper bar code on theenvelope, the envelope will continue on conveyer 34 to the end of theconveyer and be dumped into a receptacle at the package qualityassurance station 96. If the bag does not contain a literature pack,then the bag is diverted into a tote (not shown) which will then betransported by a conveyer 34 to the package quality assurance station96, where the shipping container will be assembled with the literaturepack manually 137.

As shown in the OCP station 29 of FIG. 1C, the four carriers of a rankare first received in a carrier buffer 75 from which they are loadedonto a turntable 77. An RFID tag reader (not shown) verifies that thecorrect carriers are in place on turntable 77, which selectively rotatesthe carriers into a position to have the bottles removed by robotic arm79. OCP station 29 also contains equipment 91 for packing literatureinto shipping containers, which take the form of bags 83, along with theprescription bottles of a given order. OCP station 29 also includes abagging machine 181 which presents the bags for successive orders to beloaded in sequence at a loading position. Bagging machine 181 can printa bar code identifying the order directly on each bag 83. The printeddata may include the mailing address to which the shipping container isto be sent.

Bag 83 is shown at the loading position with its mouth open. The openingof the mouth of bag 83 can be accomplished by a blower (not shown)provided as part of bagging machine 181. Conveyer 34 brings envelopes 85containing literature to be packed in shipping containers to OCP station29 in the reverse sequence that the patient orders are to be packed atthat OCP station 29 for a given rank of carriers. At OCP stations 29,literature conveyor 34 can be in the form of a literature sortationsystem of the type used in mail sortation by the U.S. Post Office. Theliterature sortation system can include a pair of belts 88 that pass theenvelopes along from station to station. Deflector 89 can optionally belocated between each pair of belts 88, and be controlled by the OCPstation controller to deflect selected literature envelopes into aliterature dispensing mechanism 91.

When a rank of carriers is directed to a given OCP station 29 by PAC 10from bottle cappers 25, PAC 10 can send an unload message to thecontroller for the OCP station 29. The unload message can contain anindication of the sequence that the orders are to be unloaded from therank of carriers at the station, as well as containing the informationas to the scheduled position of the bottles of each order in the fourcarriers of the rank of carriers to be unloaded. At the same time thatPAC 10 sends an unload message to the controller of the OCP station 29,it can send a corresponding autopublish message to printers 31. Themessage can contain the information to be printed for the completeorders contained in the rank of carriers being sent to an OCP station29. The autopublish message will also contain the sequence in which thecorresponding orders are to be unloaded at the OCP station 29. Inresponse to the autopublish message, one of the printers 31 will printliterature for the orders and deposit the literature packs for theorders on literature conveyer 34 in reverse order from that in which theorders are to be unloaded at the OCP station 29.

Each literature pack is preferably enclosed in an envelope having a diecut window through which a bar code is readable by a bar code reader 87.The bar code can be printed by an appropriate printer 31 to identify theorder for which the literature pack is printed. As the envelopescontaining literature packs are carried past the OCP station 29 in theliterature sortation system, the bar code readable through the window ineach envelope will be read by a bar code reader 87, that can verify thatthe bar code coincides with an order in the unload message received bythe controller for OCP station 29. The controller for OCP station 29will then cause deflector 89 to deflect the envelope into literaturedispensing mechanism 91. Since the conveyor brings the literatureenvelopes to an OCP station 29 in the reverse sequence that thecorresponding patient order is to be packed at the packing station, theenvelopes will be packed into the dispensing mechanism in that sequence.When bag 83 is ready to be packed at an OCP station 29, literaturedispensing mechanism 91 first inserts a literature envelope into the bag83 where it will be positioned at one side of the bag (by, e.g.,gravity). This effect is achieved by orienting the bag 83 at a slighttilted position at bagging machine 181. After the literature has beeninserted, robotic arm 79 unloads the bottles of the order from thescheduled positions in the four carriers on the turntable in accordancewith the unload message. Robotic arm 79 preferably includes a bar codereader so that each time a bottle is lifted out of a carrier by roboticarm 79, the label on the bottle is read and verified.

The prescription bottles are then loaded into the bag 83 by a bottleloading mechanism 93. When the shipping containers 83 have been verifiedand filled with a literature pack and with a patient's order, the bag issealed and dropped onto a conveyer 95 which carries the sealed shippingcontainer to a mailing area where the bag is read and logged and thenmailed to the customer. If the bag 83 does not contain a literaturepack, then the bag is diverted into a tote 99 which will then betransported by a conveyer 101 to the package quality assurance station96 where the shipping container will be assembled with the literaturepack manually.

SUMMARY OF THE INVENTION

The present invention provides additional information and features withregard to the bagging machine disclosed, for example, in FIG. 1C. Thebagging machine disclosed herein can also be advantageously used inconnection with other pharmaceutical dispensing systems, as will bedescribed herein.

The present invention includes a system that places a label on a bag.The system includes a first plurality of rollers contacting a bag filmthat includes a plurality of bags, each bag being delimited by aperforation. The first plurality of rollers define an area through whichthe bag film is conveyed, and rotate in concert in a first direction toconvey the bag film. At least one of the plurality of rollers is drivento convey the bag film. The system also includes a printer for printinga plurality of labels disposed on a backing material.

The system also includes a second plurality of rollers that contact theplurality of labels and the backing material. The second plurality ofrollers can define an area through which the plurality of labels and thebacking material are conveyed. The second plurality of rollers rotate inconcert to convey the plurality of labels and the backing material forindicia to be printed thereon. The system also includes a tamp thatreceives at least one printed label and places the printed label on thebag.

At least one of the second plurality of rollers can be under a biasingforce, and move dynamically as labels are received by said printer. Aspring can be used to provide the biasing force. In addition, a cam canbe used that moves in concert with the at least one of the secondplurality of rollers under the biasing force. The cam can engage aswitch, such that when one of the second plurality of rollers includes alabel roll, labels are dispensed from the label roll when the switch isengaged by the cam.

The system can also include a first sensor for determining a firstposition of the bag. The tamp can place the printed label on the bagresponsive to the first position determined by the first sensor.

In addition, the system can also include at least one bag openingmechanism movably mounted to open the bag subsequent to labeling. A sealbar assembly can also be provided that includes a heater element and aseal bar to seal the bag. The seal bar can move toward the bag to sealthe bag.

The at least one bag opening mechanism can include a second sensor todetermine whether the bag is in position for opening. The firstplurality of rollers can also rotate in a second direction subsequent tosealing the bag to break a perforation between the bag and a second bag.

A third sensor can be provided that detects a position of a perforationbetween the bag and a second bag. The perforation position can be usedto convey the bag a predetermined amount in the first direction to theseal bar assembly.

In addition, a third roller can be provided that separates at least oneof the plurality of labels from the backing material when the backingmaterial rotates about the third roller. A surface of the tamp caninclude a plurality of vacuum holes that facilitate maintaining thelabel on the surface prior to placing the printed label on the bag.

While a first bag can be tamped, a second bag can substantiallysimultaneously be opened by the at least one bag opening mechanism. Amotor and a belt can also be utilized to drive the at least one of thefirst plurality of rollers.

The system can also include a controller that associates at least one ofa pharmaceutical container and a literature package corresponding to aprescription order with the bag label. A robotic mechanism can be usedto place the pharmaceutical container in the bag.

A system in accordance with an embodiment of the present invention canalso include a first dancer assembly that receives and conveys a bagfilm the includes a plurality of bags, each bag being separated by aperforation. The first dancer assembly can define an area through whichthe bags are conveyed, and can include a plurality of rollers. A motorand belt can drive at least one of the plurality of rollers. The systemcan also include a printer for printing a plurality of labels disposedon a backing material.

A second dancer assembly can convey the plurality of labels and thebacking material, and define an area through which the plurality oflabels and the backing material are conveyed. A tamp can receive atleast one printed label.

A control system can associate at least one of a pharmaceuticalcontainer and a literature package corresponding to a prescription orderwith the label. A sensor system can be provided that senses a firstposition of the bag with respect to the tamp to facilitate the tampplacing the printed label on the bag, responsive to the first positiondetermined by the sensor system.

The system can also include at least one bag opening mechanism movablymounted to open the bag subsequent to labeling, and a seal bar assemblythat includes a heater element and a seal bar to seal the bag. The atleast one bag opening mechanism can include a first sensor to determinewhether a bag is in position for opening.

A second sensor can also be utilized that detects a position of aperforation between the bag and a second bag. The perforation positioncan be used to convey the bag a predetermined amount in a firstdirection to the seal bar assembly. The seal bar can move toward the bagto seal the bag. At least a portion of said first dancer assembly canrotate in a second direction subsequent to sealing the bag to break aperforation between the bag and a second bag.

A roller can be used that separates at least one of the labels from thebacking material when the backing material rotates about the roller. Asurface of the tamp can include a plurality of vacuum holes thatfacilitate maintaining the label on the surface prior to placing theprinted label on the bag.

The second dancer assembly can include a roller under a biasing forcethat moves dynamically as labels are received by the printer. A springcan provide the biasing force. In addition, a cam can be provided thatmoves in concert with the roller under the biasing force.

The system can also include a switch that is engaged by the cam, and alabel roll so that when the switch is engaged by the cam, labels aredispensed from the label roll. The label roll can be a part of thesecond dancer assembly.

A method for filling a plurality of prescription orders in accordancewith an embodiment of the present invention can include the steps oftransporting in a first direction a bag film that includes a pluralityof bags, and transporting in the first direction a plurality of labelsdisposed on a backing sheet. The name and address information of arecipient of a prescription order can be printed on a label for each ofthe plurality of bags. The label can be placed on one of the pluralityof bags from the bag film, when the corresponding bag reaches apredetermined position. The labeled bags can be opened, a pharmaceuticalcontainer with enclosed pharmaceuticals, corresponding to a prescriptionorder associated with the bag label, can be placed in the opened bag. Aliterature pack corresponding to a prescription order can also be placedin the opened bag. A method in accordance with the present invention canalso include the step of discarding a bag that cannot be opened.

The opened bag can also be sealed. The bag can be conveyed apredetermined amount in the first direction to a position where the bagis opened, responsive to detecting a perforation between two bags. Asensor can optionally be used to verify that a bag is in position foropening. Optionally after sealing, the bag can be transported in asecond direction subsequent to break a perforation between the bag and asecond bag.

Labels can be separated from the backing sheet prior to placing a labelon a bag. A vacuum can be used to hold the label in place prior toplacing the label on the bag. A label can be placed on a first bagsubstantially simultaneously while opening a second bag that already hasa label placed thereon.

There has thus been outlined, rather broadly, the more importantfeatures of the invention in order that the detailed description thereofthat follows may be better understood, and in order that the presentcontribution to the art may be better appreciated. There are, of course,additional features of the invention that will be described hereinafterand which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of otherembodiments and of being practiced and carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of description and should not beregarded as limiting.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present invention.

Further, the purpose of the foregoing abstract is to enable the U.S.Patent and Trademark Office and the public generally, and especially thescientists, engineers and practitioners in the art who are not familiarwith patent or legal terms or phraseology, to determine quickly from acursory inspection the nature and essence of the technical disclosure ofthe application. The abstract is neither intended to define theinvention of the application, which is measured by the claims, nor is itintended to be limiting as to the scope of the invention in any way.

The various features of novelty which characterize the invention arepointed out with particularity in the claims annexed to and forming apart of this disclosure. For a better understanding of the invention,its operating advantages and the specific objects attained by its uses,reference should be made to the accompanying drawings and descriptivematter in which there is illustrated preferred embodiments of theinvention.

NOTATIONS AND NOMENCLATURE

The detailed descriptions which follow may be presented in terms ofprogram procedures executed on computing or processing systems such as,for example, a stand-alone computing machine, a computer or network ofcomputers. These procedural descriptions and representations are themeans used by those skilled in the art to most effectively convey thesubstance of their work to others skilled in the art.

A procedure is here, and generally, conceived to be a sequence of stepsleading to a desired result. These steps are those that may requirephysical manipulations of physical quantities (e.g., combining variouspharmaceutical products into packages). Usually, though not necessarily,these quantities take the form of electrical, optical or magneticsignals capable of being stored, transferred, combined, compared andotherwise manipulated. It proves convenient at times, principally forreasons of common usage, to refer to these signals as bits, values,elements, symbols, characters, terms, numbers, or the like. It should benoted, however, that all of these and similar terms are to be associatedwith the appropriate physical quantities and are merely convenientlabels applied to these quantities.

Further, the manipulations performed are often referred to in terms,such as adding or comparing, which are commonly associated with mentaloperations performed by a human operator. No such capability of a humanoperator is necessary, or desirable in most cases, in any of theoperations described herein which form part of the present invention;the operations are machine operations. Useful machines for performingthe operation of the present invention include general purpose digitalcomputers or similar devices, including, but not limited to,microprocessors.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the present application showing variousdistinctive features may be best understood when the detaileddescription is read in reference to the appended drawing in which:

FIGS. 1A, 1B and 1C are exemplary diagrams illustrating a conventionalautomated pill dispenser that can utilize the bagger system disclosedherein;

FIGS. 2A-2E are exemplary diagrams illustrating aspects of an automatedpill dispensing system that can utilize the bagger system disclosedherein;

FIG. 3A is an exemplary diagram illustrating an embodiment of anautomated pill dispensing system in accordance with the presentinvention;

FIG. 3B is an exemplary diagram illustrating an aspect of an automatedpill dispenser that can be used with the present invention;

FIG. 4A is an elevation view of an exemplary bagger;

FIG. 4B is an exemplary bag feed dancer assembly of the bagger;

FIG. 4C is a cross section view of an exemplary bagger;

FIG. 5 is an exemplary embodiment of a tamp pad assembly of the bagger;

FIG. 6 is an exemplary embodiment of a seal bar assembly of the bagger;

FIG. 7 is an exemplary embodiment of a bag open finger;

FIG. 8A is a top view of an exemplary aspect of the seal bar assembly;

FIG. 8B is an elevation view of an exemplary aspect of the seal barassembly; and

FIGS. 9A, 9B and 9C, taken together, is an exemplary embodiment of aflow chart of a method of operation of the bagger.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to the presently preferredembodiments of the invention. Such embodiments are provided by way ofexplanation of the invention, which is not intended to be limitedthereto. In fact, those of ordinary skill in the art may appreciate uponreading the present specification and viewing the present drawings thatvarious modifications and variations can be made.

For example, features illustrated or described as part of one embodimentcan be used on other embodiments to yield a still further embodiment.Additionally, certain features may be interchanged with similar devicesor features not mentioned yet which perform the same or similarfunctions. It is therefore intended that such modifications andvariations are included within the totality of the present invention.

Embodiments of the present invention are directed to dispensing ordersthat include various pharmaceutical products (e.g., bottles that containcounted pills, packages that include liquid or pre-packagedpharmaceutical products and/or patient specific literatures). Inembodiments of the present invention, the term “pills” also refer totablets, capsules and other similar terms known in the art. As usedherein, the term pill can thus be used interchangeably with, forexample, the terms tablet and/or capsule.

FIGS. 2A-2E show the automated prescription filling system withautomated labeling and packaging 250 as described in U.S. patentapplication Ser. No. 10/215,249, which is incorporated herein byreference. System 250 can be referred to as a automated labeling andpackaging system (ALPS). In particular, FIG. 2A shows a system 250 thatcan include a storage device for packages 203, a dispenser for thepackages 205, a storage device for bottles filled with counted pills209, a dispenser for the bottles with counted pills 207, a storagedevice for patient specific literatures 211, a dispenser for the patientspecific literatures 213, a consolidation station 215, and a hostcomputer 201.

The system shown in FIGS. 2A-2E can also include one or more localcomputers (not shown). For instance, each of the components (e.g., 203,205, 209, 207, 211 and 213) can be connected to one or more localcomputers. The local computers in turn are optionally connected tocentral or host computer 201. In this way, the optional central or hostcomputer 201 and local computers can be configured to control thevarious components of the present invention.

A local computer can also function with a standard Programmable LogicController (PLC). A PLC typically includes an I/O card to turn on/off adevice. Accordingly, when a component is to be controlled by turning iton/off, a PLC can be used. When a large quantity of data is to beexchanged, a local computer can be used.

Central computer 201 can receive a request to fill an order, optionallyin combination with the local computer(s) and/or the various components.Alternatively, local computers can receive the request to fill an orderdirectly. In response, host computer 201 creates an order number anddetermines whether the order contains an order that requires bottles tobe filled by counting individual tablets, and whether the order containsan order that requires packages from the storage device for bottles 209.

The storage device for packages 203 stores packages that containpharmaceutical products. For example, one set of packages may contain apredetermined number of tablets (e.g., 500 tablets) of a certain drug(e.g., Allegra). Another set of example packages may include liquidpharmaceutical products. The packages can be made by original producersof drugs (e.g., Hoechst Marion Roussel). The packages can also be bulkbottles that are filled by any one of many automated (e.g., the ADDS) ormanual methods known in the art. These packages can then be shelved sothat their locations can be automatically identified. In turn, thedispenser for the packages 205 is configured to automatically identifythe location of any package with a certain type of drug, dosage and/orquantity and configured to pick one or more packages from the identifiedlocation. In other words, a package contains a pharmaceutical productwithout having been pre-designated for any specific order when thepackage was created.

In operation, the command to locate and pick one or more packages isreceived from host computer 201. The dispenser for packages can also beconnected to its own local computer to perform the necessary functionsto locate and pick one or more packages in accordance with the commandfrom host computer 201. Packages stored in the storage device forpackages 203 are not designated for any specific patient. In otherwords, any package can be picked to fill an order of a patient as longas the type of drug, dosage and/or quantity are matched with the order.

FIG. 2A can also include a standard sensor or a standard counter toindicate when a specific type of package is out of stock in the storagedevice for packages 203. These sensors or counters can be present ateach location (or a substantial number of them). The signals from thesensors or counters can be communicated to, for example, the central orhost computer 201 via the local computer. In turn, central or hostcomputer 201 can notify an operator or system to replenish the specificpackages and/or stop the process of filling orders that require thespecific type of package that are out of stock in the storage device forpackages 203. In addition, or optionally, central or host computer 201can send a query to the storage device for packages 203 regardingwhether a certain number of certain packages are available to bedispensed. In response, the storage device for packages 203, or incombination with its local computer, can send a response based oninformation from the sensors and/or counters. Alternatively, sensors maybe placed on a picking device (e.g., a robot arm) to provide the similarfunctionality. In yet another alternative, sensors are not utilized andthe system keeps logical control by knowing how many packages have beenplaced in a channel and how many packages have been removed from thechannel.

The dispenser for bottles 207 is configured to receive bottles thatcontain specific number (e.g., 1-500 or more) of pills for a specificorder. For example, one bottle may include 350 tablets of one type ofdrug for patient A, while another bottle may include 600 tablets ofanother type of drug for patient B. The bottles can be filled by anyautomatic dispensing mechanisms known in the art (e.g., the system shownin U.S. Pat. No. 5,771,657, which is incorporated herein by reference).Bottles can also be manually filled (by, e.g., a pharmacist).

If an automatic dispensing system is used, central or host computer 201sends commands to fill bottles with certain number of pills for acertain type of drug. Once they are filled, the bottles are stored inthe storage device for bottles 209. In a similar fashion, in a manualsystem, the dispensing person would receive an instruction to countcertain number of tablets for a certain type of drug. The person fillsbottles according to the instructions and forwards the bottles to thestorage device for bottles 209.

Once the storage device for bottles 209 receives all the bottlesnecessary to fill an order, the storage device for bottles 209 or inconnection with its local computer sends a message to, for example, thecentral or host computer 201 indicating that the bottle portion of theorder has been filled. For example, an order to be filled may require1450 pills of a certain type of drug. In this example, the storagedevice for packages 203 may already have two packages each with 500pills of the drug. If so, one bottle with 450 pills of the drug isnecessary to fill the bottle portion of the order. (If one bottle cannotreceive all 450 pills then more than one bottle would become necessaryto provide the 450 pills).

The storage device for literature packs 211 contains literature to bepackaged with specific orders. For example, a set of literature packsfor one order may include information relating to each of the prescribeddrugs, how often each drug must be taken, billing information, specialinstructions from the prescribing doctor, insurance information,refilling information and/or general information, for example health ornotification of other services. The set of literature packs is thenpackaged per order and collected in the storage device for literaturepacks 211. Once the necessary literature packs are created, the storagedevice for literature packs 211, or in combination with its localcomputer, can notify the host computer 201 that the literature pack hasbeen printed.

Upon receiving various information from the storage device for packages203, storage device for bottles 209 and storage device for literaturepacks 211, computer 201 then sends instructions to the dispenser for thepackages 205, dispenser for bottles 207 and dispenser for literaturepacks 213, or to their local computers, to dispense necessary bottle(s),package(s) and literature pack(s) to fill one or more orders. Thedispensed bottle(s), package(s) and literature pack(s) are thenconsolidated by the consolidation station 215 and then sent, distributedor mailed out directly or indirectly to patients associated with theorders.

FIG. 2B shows an exemplary block diagram of aspects of system 250.Picking robot 225 can pick pharmaceutical containers from pick racks203. Induct belt 1403 is configured to receive packages picked andunloaded by the picking robot 225. Received packages are thentransported to a separation and accumulation belt 1405 configured to putgaps between the packages. The separation and accumulation belt 1405then moves the packages into a set of barcode scanners in barcode tunnel1407. Tunnel 1407 scanners are configured to detect and read barcodesfrom, for example, any of five exposed sides of the packages. (Since thepackages are boxes, when the packages are placed on the belt 1405, fivesides are exposed other than the side that touches the belt.) In suchembodiments, when the packages are replenished into the shelves, theirbarcodes should preferably not be on the bottom. In some otherembodiments, only a top side can be scanned as long as the packages areplaced into the shelves so that their barcodes are on the top.Accordingly, any combination of barcode readers can be used as long asbarcodes on the packages can be detected and read. It should be notedthat in some embodiments of the present invention, belt 1405 can betransparent so that barcodes from the bottom side of the packages canalso be detected and read by a barcode reader located below the belt1405.

When barcodes are read, they can be verified by a local computer, whichensures that the scanned package actually belongs to the order that isabout to be filled by the consolidation station 215. After the barcodescanners are used, the images of the packages are captured by a camera(not shown). The images are then sent to the local computer to determinethe shape and orientation of the packages as they lay on belt 1405.Based on the determined shape, height and orientation, the localcomputer commands robot 1505 arm to pick up the package from belt 1405.An example of conventional computer vision software includes Adept AIMSystem, Motionware, Robot & Vision, Version 3.3B-Jun. 9, 1999, U.S. Pat.No. 4,835,730, incorporated herein by reference.

The local computer causes a patient label to be printed by the patientlabeler 1501 for each package. While a package is picked up by the robot1505 and being transported, its label is affixed to the package. Thenrobot 1505 can move the package next to the barcode reader 1503. Thepresence of a correct label is determined by the label barcode reader1503. In addition, robot 1501, label barcode reader 1503, and theirlocal computer can also be configured to cooperate with each other todetect labels and reject any packages without a label or with anincorrect label. Once, the package is determined to have a correct labelaffixed thereto, robot 1505 can drop the package into the bag opened in(and by) bagger 181.

With respect to bottles, metal detect conveyor 1509 can have a metaldetector 1511 which can determine the presence of metallic substances inthe bottles. Bottles with metallic substances can be rejected. Thebottles belonging to one order are then placed into a standard bottlemagazine 1513 by a standard pick-and-place device 1507 (e.g., a robot).An example of pick-and-place devices includes Stelron, Model:SVIP-A-M-P-6.00, X-2.00 Y-spec, U.S. Pat. No. 3,703,834, Mahwah, N.J. Inthis example embodiment, bottle barcode reader 1525 is provided toensure that correct bottles have been delivered to the bottle magazine.Once all the bottles have been loaded to the bottle magazine, they canbe released into a corresponding bag 83 held (and opened) by bagger 181.

With respect to the literature packs, they are transported to bagger 181via literature conveyor 221. As the packs arrive at bagger 181, theirbarcodes are detected and checked by literature barcode reader 1517 toverify that correct literature packs are to be included in the bag 83.As the literature packs arrive, they are discharged into bag 83 as willbe discussed herein.

In an embodiment, conveyor belt 221 can have three positions. Position 1designates the position on the belt 221 in which its literature pack isready to be disposed into the bag 83 at bagger 813. Position 2designates the position on the belt 221 in which its literature pack canbe discarded if some error is detected. Position 3 designates theposition on the belt 221 in which a barcode reader 1517 can detect andread the barcode of the literature pack.

Literature handling logic can report on the status of the literaturepacks in the three positions. Consolidation logic can instructliterature handling logic to perform one or more tasks (e.g., accept orreject certain literature packs and/or advance the conveyor belt 221).

With regard to bagger 181, bags 83 are fed from the bag supply 265 (FIG.2E), for example, one at a time. As bags 83 move up through bagger 181,a label or information about the order that is about to be filled isplaced on the bag 83. For example, standard tamp 255 (FIGS. 4A and 5)can be used to place the label on a bag 83. The label or information isthen detected and read by a scanner or barcode reader 251, which canverify that the correct label is printed and/or the label is properlyaffixed to the bag 83. As will be discussed herein, bagger 181 can thenopen bag 83 to place one or more literature packages and/orpharmaceuticals therein.

If bagger 181 seals a bag 83, the sealed bag 83 can be placed on aconveyor belt 1519 for subsequent distribution to a patient. If bagger181 leaves a bag unsealed, the unsealed bags can be placed in a tote,which is placed on tote conveyor 1521. The tote is then transferred toan operator who can then completely fill the order by manually addingany (additional) required package(s).

FIG. 2C is a top view of a schematic illustrating an exemplaryconsolidation station, as is shown in block diagram for in FIG. 2B. Inparticular, FIG. 2B illustrates the bottle storage table 223 for thebottles, picking robot 225 and conveyor belt 221 for the literaturepacks. The bottles, packages and literature packs are combined in theorder consolidation station 227, and put into one or more bags 83 at thebagger 181.

In operation, bottles filled with counted pills are stored at bottlestorage table 223. When a complete set of bottles is received by thebottle storage table 223, its local computer notifies computer 201 thatall the bottles for a particular order have been received. In response,computer 201 causes literature packs for the order to be printed andsent to the dispatch unit (either in a batch or individually). When theliterature packs are received, they are organized such that literaturepacks for one order are next to each other. A dispatch unit (not shown)can determine the sequence of orders that the literature packs arereceived by reading identification codes affixed (or printed) on theliterature packs. The dispatch unit then sends the literature packs, asthey are received and sequenced, to the order consolidation station 227via the conveyor belt 221. The dispatch unit can also notify thecomputer 201 the sequence of literature packs.

Upon receiving the information from the dispatch unit, computer 201 caninstruct the bottle storage table 223 to release corresponding bottles,and picking robot 225 to pick corresponding packages of the order. Theexample embodiment is further configured such that the bottles, packagesand literature packs all arrive at bagger 181 simultaneously for eachorder, although bagger 181 can optionally receive them at differenttimes in storage locations for later bagging. This configuration allowsbagger 181 to put the bottles, packages, and literature packs into oneor more bags automatically. In alternative embodiments, computer 201 maybe more involved or less involved based upon specific filling programs,volume, etc.

FIG. 2D illustrates the steps taken by the various components, theirlocal computers, and computer 201 in the order consolidation station215. In particular, bottles belonging to one order number are receivedfrom bottle storage table 223 (step 281). The received bottles are runthrough the metal detector 1511 (step 283). The bottles are then mountedon bottle magazine 1513 by pick-and-place device 1507 (step 285).Simultaneously, packages belonging to the same order number are receivedfrom storage device for packages 203 (step 287). A label is affixed toeach of the received packages (step 289). Again simultaneously orsubstantially simultaneously, conveyor belt 221 moves literature packsbelonging to the same order number to bagger 181. When all the itemsarrive, they are disposed into one or more bags 83 at the bagger 813.

If any error is detected, the items belonging to the same order numberare all sent to a quality assurance station. If the error cannot beresolved, the order is cancelled and re-ordered or re-assembled. Hostcomputer 201 reinitiates the process from the beginning to fill theorder again. The example errors can be a rejected bottle because ametallic substance was detected, a patient label not being affixed to apackage, and/or incorrect literature packs being delivered, etc.

FIG. 2E is diagram illustrating an exemplary high level view of bagger181, which includes a supply of bags 265, a printer 260, tamp 255, ascanner 251, a mechanism 245 to open a bag and hold it open and a sealbar assembly 240 to seal the bag. In operation, bags are fed from thebag supply 265. As the bags move up through the bagger 181, a label orinformation about the order that is about to be filled is placed on bag83. For example, the label may be printed and then pressed against thebag by the tamp 255. The label or information is then detected and readby scanner 251, which can determine whether the correct label is printedand/or the label is properly affixed to bag 83. Bag 83 is then opened toreceive one or more prescriptions and optionally one or morecorresponding literature packages.

If bag 83 contains all the items necessary to fill the order, then thebag 83 is sealed. Optionally, bag 83 is not sealed, if an error isdetected. If one or more manually picked packages are required, then bag83 is left unsealed.

FIG. 3A is an exemplary diagram illustrating an automated pilldispensing system 310 in accordance with an embodiment of the presentinvention. In operation, orders (e.g., orders to fill prescriptions) arereceived by a host computer 9 which forwards the orders to a distributedcomputer system that can include, for example, any standard computersuch as a central computer called Pharmacy Automation Controller 10(PAC). PAC 10 maintains an order file of the information about eachprescription to be filled that can include information needed to filleach prescription. The order file can, for example, be used to prepare aprescription label for each bottle/container (hereinafter bottle). Theorder file can also be used to facilitate printing literature that canbe placed in a shipping container with the bottle(s). PAC 10 can alsoupdate the order file to maintain a record of the current status of eachprescription being filled as it progresses through the automated system.

PAC 10 can control a set of Print, Apply and Load (PAL) stations 14which print prescription bottle labels, apply the labels to bottles, andload the labeled bottles onto bottle carriers that preferably receivethe bottles in schedules locations. PAC 10 can also control a carrierconveyer system 21 that carries the bottle carriers to different partsof system 100, and automatic drug dispensing machines 23 that dispensetablets and/or capsules into the bottles in the bottle carriers as theyare carried by conveyer system 21. In addition, PAC 10 controls bottlecappers 25 that apply caps to the bottles, and OCP stations 29 thatunload bottles from the carriers and place them in shipping containerscorresponding to a patient order. Further, PAC 10 can control literatureprinters 31 which print literature, for each prescription order, thatcan be enclosed in an envelope. Finally, PAC 10 can utilize a bar codethat identifies the prescription order. The bar code can show through awindow in the envelope. Envelopes can be placed on a literature conveyer34 which carries the envelopes from the literature printers 31 to theOCP stations 29.

Conveyer system 21 carries the bottles in the carriers from PAL stations14 through the automatic drug dispensing machines 23 to bottle cappers25, and then from bottle cappers to OCP stations 29. Alternativesequences may optionally be used. Conveyer system 21 also carries emptycarriers back to PAL stations 14. From bottle cappers 25, conveyers 56feed the carriers onto an endless conveyer loop 71 which transports, forexample, four carriers of a rank to one of, say, six OCP stations 29.Other numbers of OCP stations 29 can also be utilized. OCP stations 29each also have a literature dispensing mechanism, which inserts theprinted literature into each shipping container with the filled andcapped prescription bottles.

Patient prescription bottles that are to be automatically filled withthe prescription drugs can be introduced to the automated system byhoppers (not shown, but the same as or similar to hoppers 37 shown inFIG. 1B) which receive the bottles in bulk form and automatically feedthe bottles to unscramblers 39. For example, one hopper 37 and one ofthe unscramblers (not shown, but the same as or similar to anunscrambler 39 shown in FIG. 1B) can be used for relatively largebottles (e.g. 160 cc), and the remaining hoppers and unscramblers can beused for small bottles (e.g., 110 cc). Small bottles preferably can beused for a majority of the prescriptions. Any prescription orders thatcannot be filled by using a large bottle can be filled by using multiplelarge and/or small bottles. In the unscramblers, the bottles aresingulated and oriented so that the bottle opening first faces downward.The bottles are then, for example, righted and directed to PAL stations14 on bottle conveyers (not shown, but the same as or similar toconveyors 41, 43 shown in FIG. 1B), one for large bottles and one forsmall bottles.

Conveyers 45, under control by PAC 10, carry the bottle carriers fromthe four PAL stations 14 to carrier buffers at the entrances of the fourautomatic drug dispensing machines 23 in which the tablets or capsulesof the prescriptions are automatically dispensed into the prescriptionbottles under the control of PAC 10. Because of the organizationprovided by the carriers, the bottles are arranged into four columnsapproaching each automatic dispensing machine 23. Since there are, forexample, four automatic dispensing machines 23, 16 parallel prescriptionbottle columns can approach the dispensing machines. In this embodiment,the four automatic drug dispensing machines each have 384 drugdispensers arranged four columns wide and 96 rows deep to provide atotal of 1,536 pill dispensers. The automatic drug dispensing machinesare similar to those described in the U.S. Pat. No. 5,660,305, which ishereby incorporated by reference. Each dispensing lane is divided into32 buffer assemblies, each containing twelve drug dispensers orientedsix on each side of a conveyer within the dispensing machine. Otherstandard pill dispensers may optionally be used.

The carrier will be released by PAL station 14 onto a conveyer 45 whichcarries the carrier loaded with the labeled empty prescription bottlesto an automatic dispensing machine 23, of which there are, for example,four, one for each PAL station 14. When a carrier moves out of the lastrow position in a dispensing machine, all of the prescription bottles inthat bottle carrier should be filled and a conveyer 56 transports theprescription bottles now filled with the prescriptions to a bottlecapper 25.

Bottle quality assurance area 109 has several stations at which, forexample, pharmacists can scan the bar code on the bottles and visuallyinspect the contents of the bottles. The scan of the bottle bar codewill bring up a display on the pharmacist's terminal which preferablyincludes all the information regarding the particular prescription andorder. Such information can include, for example, the drug name, andinstructions which identify the reason for the verification. All of thebottles that pass this inspection can be inserted by the pharmacist on abottle stream conveyer 111 to send the inspected bottles to the BSPstation 112. Conveyer 108 leads to a star wheel diverter mechanism 114which, optionally under the control of a controller for BSP station 112,deposits the bottle in a bottle stream conveyer 116 leading to thebottle quality assurance area 109 or into a bottle stream conveyer 118leading to BSP station 112.

If the literature pack is on conveyer 34, but because of failure of thebar code reader (not shown) or the literature sorting mechanism (notshown), does not get diverted at BSP station 112, conveyer 34 will carrythe literature package to package quality assurance area 96 where it canbe manually added to the package or alternatively re-inserted into theprocess for grouping with the appropriate order. If, because of amalfunction, a literature envelope is not deflected by a deflector 89(FIG. 1C), because of, for example, an improper bar code on theenvelope, the envelope will continue on conveyer 34 to the end of theconveyer and be dumped into a receptacle at the package qualityassurance station 96. If the bag does not contain a literature pack,then the bag is diverted into a tote (not shown) which will then betransported by a conveyer 34 to the package quality assurance station96, where the shipping container will be assembled with the literaturepack manually 137. Alternatively, the entire order may be aborted andattempted again as described above.

As shown in the OCP station 29 of FIG. 1C, the four carriers of a rankare first received in a carrier buffer 75 from which they are loadedonto a turntable 77. An RFID tag reader (not shown) verifies that thecorrect carriers are in place on turntable 77, which selectively rotatesthe carriers into a position to have the bottles removed by robotic arm79 or other standard mechanism. OCP station 29 also contains equipment91 for packing literature into shipping containers, which take the formof bags 83, along with the prescription bottles of a given order. OCPstation 29 also includes a bagging machine 181 which presents the bagsfor successive orders to be loaded in sequence at a loading position.Bagging machine 181 can print a bar code identifying the order directlyon each bag 83. The printed data may include the mailing address towhich the shipping container is to be sent.

Bag 83 is shown at the loading position with its mouth open. The openingof the mouth of bag 83 can be accomplished by a standard blower (notshown) provided as part of bagging machine 181 or other standardmechanisms. Conveyer 34 brings envelopes 85 containing literature to bepacked in shipping containers to OCP station 29 in the reverse sequencethat the patient orders are to be packed at that OCP station 29 for agiven rank of carriers. At OCP station 29, literature conveyor 34 can bein the form of a standard literature sortation system of the type usedin mail sortation by the U.S. Post Office. The literature sortationsystem can include a pair of belts 88 that pass the envelopes along fromstation to station. Deflector 89 can optionally be located between eachpair of belts 88, and be controlled by the OCP station controller todeflect selected literature envelopes into a literature dispensingmechanism 91.

When a rank of carriers is directed to a given OCP station 29 by PAC 10from bottle cappers 25, PAC 10 can send an unload message to thecontroller for the OCP station 29. The unload message can contain anindication of the sequence that the orders are to be unloaded from therank of carriers at the station, as well as containing the informationas to the scheduled position of the bottles of each order in the fourcarriers of the rank of carriers to be unloaded. At the same time thatPAC 10 sends an unload message to the controller of the OCP station 29,it can send a corresponding autopublish message to printers 31. Themessage can contain the information to be printed for the completeorders contained in the rank of carriers being sent to an OCP station29. The autopublish message will also contain the sequence in which thecorresponding orders are to be unloaded at the OCP station 29. Inresponse to the autopublish message, one of the printers 31 will printliterature for the orders and deposit the literature packs for theorders on literature conveyer 34 in reverse order from that in which theorders are to be unloaded at the OCP station 29. Other sequences and/ororders of the steps described above may optionally be used.

Each literature pack is preferably enclosed in an envelope having a diecut window through which a bar code is readable by a bar code reader 87.The bar code can be printed by an appropriate printer 31 to identify theorder for which the literature pack is printed. As the envelopescontaining literature packs are carried past the OCP station 29 in theliterature sortation system, the bar code readable through the window ineach envelope will be read by a bar code reader 87, that can verify thatthe bar code coincides with an order in the unload message received bythe controller for OCP station 2. The controller for OCP station 29 willthen cause deflector 89 to deflect the envelope into literaturedispensing mechanism 91. Since the conveyor brings the literatureenvelopes to an OCP station 29 in, for example, the reverse sequencethat the corresponding patient order is to be packed at the packingstation, the envelopes will be packed into the dispensing mechanism inthat sequence. When bag 83 is ready to be packed at OCP station 29,literature dispensing mechanism 91 first inserts a literature envelopeinto the bag 83 where it will be positioned at one side of the bag (by,e.g., gravity). This effect is achieved by orienting the bag 83 at aslight tilted position at bagging machine 181. After the literature hasbeen inserted, robotic arm 79 or other mechanism unloads the bottles ofthe order from the scheduled positions in the four carriers on theturntable in accordance with the unload message. Robotic arm 79preferably includes a bar code reader so that each time a bottle islifted out of a carrier by robotic arm 79, the label on the bottle isread and verified.

The prescription bottles are then loaded into the bag 83 by a standardbottle loading mechanism 93. When the shipping containers 83 have beenverified and filled with a literature pack and with a patient's order,the bag is sealed and dropped onto a conveyer 95 which carries thesealed shipping container to a mailing area where the bag is read andlogged and then mailed to the customer. If the bag 83 does not contain aliterature pack, then the bag is diverted into a tote 99 which will thenbe transported by a conveyer 101 to the package quality assurancestation 96 where the shipping container will be assembled with theliterature pack, for example, manually. Alternatively, the order can beaborted, and attempted again through the automated process describedherein. As shown in FIG. 3A, bagger 181 can be used with either or bothof system 100 and ALPS system 250.

FIG. 3B is similar to FIG. 1B, and shows exemplary aspects of theautomated pill dispensing system 310 shown in FIG. 3A. In operation, oneor more literature packs can be printed on a printer 31, and sent to acollator 32 for collation into individual literature packs. More thanone collator 32 can optionally be used. Once literature packs arecollated, they can travel, for example, on a standard pinchbelt conveyor33 to a literature pack sorter 35, where they are sorted into literaturepack batches. Although two literature pack sorters 35 are shown, anynumber of literature pack sorters can be utilized to suit, for example,cost and/or volume considerations.

On command from, for example, an OCP station 29, the literature packbatches can optionally be manually transferred from the one or moresorters 35 to a dispatch unit 36. Again, any number of dispatch unitscan be utilized to accommodate, for example, manufacturing, facilitysize and/or cost requirements or constraints. Dispatch units 36 can feedthe literature packs to an OCP station 29.

When system 310 detects (and/or suspects) a problem with an order (e.g.,a wrong shipping address, incorrect prescription drug(s), and/orincorrect prescription quantity), an OCP station 29 can place the orderin a bag, and divert the bag into, for example, a standard tote (notshown). The tote can be transported by, for example, conveyer 101 topackage quality assurance station 96, where a quality assurance personcan inspect the order and correct anything that might be wrong (asdiscussed above) with the order. After inspection and corrective action,the quality assurance person at station 96 can take additional action(s)to ensure that the properly filled order is shipped to thepatient/client. An embodiment of the bagger 181 in accordance with thepresent invention (as will be discussed herein), can interface with, forexample, a dispensing unit 36 and an OCP station 29, to perform thebagging operations described herein. A bagger 181 (FIG. 4A) canoptionally interface with, for example, each OCP 29—dispatch unit 36combination. Turning now to FIG. 4A, an exemplary side view of bagger181 is shown. Bagger 181 is a separate unit that, in an embodiment, isdetachable and/or interchangeable with, for example, an OCP station 29(of FIGS. 1A-1C) and/or ALPS 250 (of FIGS. 2A-2E). Bagger 181 feedsincoming bags 83, preferably but optionally from a preloaded fan-foldedblank bag stock (not shown) that can be stored in bag supply 265. Bags83 are advanced by motor 453 through a series of rollers 2 a, 2 b, 2 c,to bag feed dancer 407 and associated rollers 2 d-2 i. Motor 453 canoptionally be a variable speed motor. FIG. 4B shows a larger view of thebag feed dancer 407 shown in FIG. 4A. FIG. 4C shows a view of bagger181, showing rollers 2 d-2 i. In FIG. 4A, arm 411 a is shown on a firstside of rollers 2 g, 2 h, 2 i. In FIG. 4C, arm 411 b is shown on anopposing side of rollers 2 g, 2 h, 2 i.

Bag feed dancer 407 accumulates bag 83 film and provides tension so thatthe perforation that separates the two bags 83 will not be torn duringbag indexing (as will be described herein). Motor 453 can be used tolock, as well as drive, roller 2 c. When roller 2 c is locked, motor 455can be used to activate index roller 7 a which, in combination withroller 7 b, transports the bag 83 film. Because rollers 2 b and 2 c arelocked, dancer 407 is raised when index roller 7 a is activated. Whendancer 407 is raised a predetermined amount (to, e.g., account for thelength of the bags 83), a sensor 8 (e.g., a limit switch) located aboveshaft 6 can be used to activate motor 453. Then, motor 453 is activatedso rollers 2 b, 2 c feed bag 83 film into dancer rollers 2 d-2 i untildancer 407 drops a sufficient amount for sensor 8 to stop motor 453.Rollers 2 b, 2 c, can optionally be separated each cycle by pneumaticcylinder 409, to allow bag 83 film to realign between rollers 2 b, 2 c.

As bags 83 are being transported toward printer 260, label dancerassembly 463 controls label tension into printer 260. An embodiment oflabel dancer assembly 463 includes roller 42 a, dancer 42 b, and roller42 c, which can be used to accumulate labels between label roll 464 andprinter 260. A control computer (not shown) can supply data in aconventional manner to printer 260. In an embodiment, printer 260 can bea SATO label printer (SATO America, Inc., Charlotte, N.C.).

Printer 260 prints the correct label for bag 83 corresponding to aprescription order. Printer 260 can receive data from, for example,computer 9 (FIG. 3A) and/or computer 201 (FIGS. 2A, 3). At the start ofa print cycle, a drive (not shown) of printer 260 rolls a label back (inthe direction of arrow 468) approximately 0.25 inch to optionally allowprinting of the leading edge of the label. Printer 260 then pulls thelabel forward (in the direction of arrow 469) from the label dancerassembly 463 and across the print head, optionally at a rate of, forexample, 6 inches per second. While the label moves forward, motor 465locks label roll 464, which causes dancer 42 b and cam 44, each mountedon shaft 88, to drop in the direction of arrow 466. Dancer 42 b ispreferably under spring tension, biasing dancer 42 b in the direction ofarrow 467. Motor 465 can optionally be connected to label roll 464 by,for example, a belt (not shown).

As cam 44 moves in the direction of arrow 466, it comes into contactwith, for example a switch (not shown), optionally mounted on surface89. When cam 44 contacts the switch, motor 465 is activated to turnlabel roll 464 to dispense another bag 88, which causes dancer 42 b torise in the direction of arrow 467. The printed label can exit printer260, and optionally rotate about, for example, a standard scraper bar(not shown), where the label backing material is stripped andaccumulated on label take-up roller 46.

After printing, a barcode scanner (not shown) can optionally be utilizedand be positioned downstream of printer 260 to read the barcode on theprinted label to verify that the label was printed correctly before thelabel is delivered to tamp 255. If the label did not print correctly,bag 81 and the label can be rejected, and a new label can be printed andplaced on the next bag 81. After the label is printed and optionallyverified, the label proceeds to tamp 255, which stages the printed labeland applies the label to bag 83.

Referring now to tamp 255 shown in FIG. 5, a grid arrangement of holes506, optionally supplied with vacuum in the direction of arrow 510, canbe used to hold the label on tamp pad 504 until bag 83 is in position.Following an index servo move (explained herein) that places bag 83 intoa position for label application, tamp pad 504 moves in the direction ofarrow 508 to place the label on bag 83 positioned therebeneath. Thevacuum air can be turned off (or reduced) when tamp pad 504 reaches bag83. Proximity sensors (not shown) can optionally be used to sense tamppad 504 movement. For example, a reflector (not shown) can be placed ator near an edge of tamp pad 504, and an emitter/receiver (not shown) canbe placed to operate in conjunction with the reflector.

In one embodiment, when the label is in proper position on tamp pad 504,the emitter/receiver will not detect a return signal from the reflector,thereby indicating that the label is in a proper position. If thereflector and emitter/receiver detect that label is not correctlypositioned on tamp pad 504, bagger 181 can fault. After an operatoracknowledges the label position fault, the fault will clear and bagger181 can then perform the tamping. A valve, optionally connecting withpneumatic cylinder 502, can be used to cycle tamp pad 805 up and down.

After labeling, and referring back to FIG. 4A, index rolls 7 a, 7 b pullbag 83 film (in the direction or arrow 469) from infeed dancer 407 toindex a bag 83 prior to opening. Index rolls 7 a, 7 b can also retractbag 83 (in the direction of arrow 468) to break the bag 83 along aperforation. Index rolls 7 a, 7 b can be driven by, for example, astandard Yaskawa servo motor 455 (Yaskawa Electric America, Inc.,Waukegan, Ill.) and associated control system (not shown).

To perform an index, a perforation between bags 83 is detected by, forexample, a standard optical scanner 13. In an embodiment, a KeyenceFS-V1 fiber optic sensor (Keyence Corporation, Osaka, Japan) can be usedas the optical scanner 13. The bagger control system (not shown) canactivate motor 455 so that index rolls 7 a, 7 b move bag 83 until aperforation is detected by scanner 13. The perforation detected willpreferably be on a trailing end of bag 83. When a bag 83 perforation isdetected, the position of the perforation is also known by the baggercontrol system. Since the length of the bag 83, bag 83 position, and theposition of, for example, seal bar assembly 240 are known, the baggercontrol system can activate motor 455 to forward the bag 83 perforationa predetermined amount (e.g., an absolute move) such that theperforation is positioned so that fingers 608 a, 608 b (FIG. 6) cangrasp the bag 83 perforation and open the bag 83. In an embodiment,computer 9 and/or computer 201 can also be used to control indexoperations.

In particular, and referring now to FIG. 6, when a bag 83 is fed to loadposition 604, fingers 608 a, 608 b, in conjunction with jaw assembly451, move in the direction of arrow 622. Upon grasping a portion of bag83 at or near, for example, a perforation of bag 83, fingers 608 a, 608b move in the direction of arrow 621 to open bag 83. In an embodiment,while one bag 83 is being tamped to have a label placed thereon, anotherbag, already having been tamped, is in load position 604.

In an embodiment, jaw 451 can be controlled by a controller (not shown),optionally configured to cut power to jaw 451 when, for example, anemergency stop button (not shown) is activated and/or a guard door (notshown) is opened. The controller is also preferably configured so that,if stopped, jaw 451 position is held, and bagger 181 can resume itsprevious cycle upon restarting. For example, when power to jaw 451 isrestored (e.g., after an emergency stop), jaw 451 can be sent to a“home” position. If action was taken to stop the cycle (e.g., a “CycleStop” button is pressed), jaw 451 can return to its last position, andthe bagger cycle can resume when action is taken to start the cycle(e.g., a “Cycle Start” button is pressed).

Fingers 608 a, 608 b can be controlled by pressure regulated pneumaticvalves (not shown) to pull bag 83 open (in direction of arrow 621) forfilling. Fingers 608 a, 608 b can, for example, optionally rotate aboutan axis (not shown) of jaw 451. As jaw 451 moves in the direction ofarrow 621 to open a bag 83, fingers 608 a, 608 b can be timed to contacta perforation of bag 83. As shown in FIG. 4A, jaw 451 is optionally cam3 driven by, for example, motor 4, and belt 11. Motor 4 can optionallybe a standard Yaskawa servo motor.

A vacuum assist suction cup (not shown) can optionally be provided, forexample, at or near the center of jaw 451 to facilitate opening bag 83.The vacuum can be used to pull bag 83 perforation open (in the directionof arrow 621) in cooperation with fingers 608 a, 608 b. As the vacuumand/or jaw 451 move to open bag 83, fingers 608 a, 608 b can, forexample, rotate about an axis to contact bag 83 perforation, and openbag 83.

In an embodiment, fingers 608 a, 608 b and axle can be charged (e.g.,with 24 VDC) and electrically isolated from ground by a rubber coupling(from e.g., Lovejoy Corporation, Downers Grove, Ill.). As shown in FIG.7, a spring loaded pin 702 can be provided under fingers 608 a, 608 b toprovide a path to ground for the signal, indicating that bag 83 is notpresent under fingers 608 a, 608 b and that bag 83 is not properlyopened.

During the bag 83 open cycle, bagger 181 can try, for example, up tothree times (or any other number of predetermined times) to properlyopen bag 83. If bag 83 cannot be opened, bag 83 can be ejected, and anew bag 83 can be indexed to begin the cycle again. If bag 83 slips outor is otherwise removed from under finger 608 a, 608 b during thefilling cycle, allowing a path to ground for the signal (e.g., 24 VDC),a “Loss of Grip” alarm can optionally be generated.

Referring back to FIG. 6, as fingers 608 a, 608 b are opening bag 83,fingers 608 a, 608 b can optionally be positioned to keep the outsideedge of bag 83 contacting jaw 451 open to maximize the opening availablefor dispensing product(s) 630 into bag 83. Fingers 608 a, 608 b canclose (return to center “home” position) as jaw 451 begins to move inthe direction of arrow 622 to complete bag 83 sealing. Motor 4 and cam 3can then be used to move jaw 451 toward seal bar assembly 240.

Once bag 83 has been filled with one or more literature packs and/or oneor more pharmaceutical containers, index rolls 7 a, 7 b shown in FIG. 4a rotate in the direction of arrow 468 to break the bag 83 perforation.

Seal bar assembly 240, shown in FIGS. 6, 8A and 8B, seals bag 83 afterfilling. FIGS. 8A and 8B show a top view and elevation view,respectively, of seal bar assembly 240. A temperature controller (notshown) can be used to heat and control heater element 804 a, 804 b shownin FIGS. 8A and 8B to maintain seal bar 802 at a specific set pointtemperature (e.g., approximately 350-420 deg. F.) to melt or fuse bag 83film. The set point temperature can optionally be manually entered intothe temperature controller, which cycles power on/off through an outputcontact in the controller, to heat the heater element 804 a, 804 b asrequired to maintain the seal bar 802 temperature at or near the setpoint. In an embodiment, a “Seal Bar Temp. Out of Range” alarm can soundwhen, for example, seal bar 802 temperature deviates more than apredetermined amount from the set point (e.g., more than +/−2 deg).Fingers 608 a, 608 b can also optionally serve to keep bag 82 spreadduring sealing to prevent wrinkles. Upper housing 806 a and lowerhousing 806 b partially surround heater element 804 a, 804 b and rod802.

To seal bag 83, jaw 451, for example, moves in the direction of arrow622 shown in FIG. 6, to close bag 83. When jaw 451 has moved asufficient distance in the direction of arrow 622, a seal bar valve (notshown) can be used to power, for example, an air cylinder 808 to pushrod 802, heater element 804 a, 804 b in the direction of arrow 820,preferably a predetermined distance (e.g., one half inch) and for apredetermined time (e.g., 0.25 seconds), thereby causing bag 83 to meltand/or fuse together. Other standard sealing processes may optionally beused.

Seal bar assembly 240 can then move in the direction of arrow 822 toreturn to its rest position. A proximity sensor can optionally beutilized to verify that seal bar assembly 240 has moved properly duringthe cycle. Once bag 83 is sealed, it can be placed onto, for example, adischarge conveyor (e.g., conveyor 108 shown in FIG. 1B and/or conveyor1519 shown in FIG. 2B) for transfer to, for example, the mail conveyoror placement into a tote, as appropriate.

Tension is maintained when bags 83 are in contact with infeed dancers 2d-2 i. Tension can cause bag 83, for example, to be pulled backward (inthe direction of arrow 452) after bag 83 has been dropped from seal barassembly 240 so that the next bag label can be indexed and tamped (aspreviously discussed) in the correct position on the next bag 83.Tension control screws (not shown) can optionally be provided on, forexample, each side of upper roller 2 b to keep bags 83 aligned intodancer 407.

As shown in FIG. 4A, a docking system 470 can be used to properlyposition and secure bagger 181 to an OCP station 29. The docking station470 advantageously allows interchangeability of baggers 181 betweenvarious OCP stations 29.

In an embodiment, an OCP station 29 can have pre-positioned floor trackguides to direct the guide wheels 471 of bagger 181 into position. Oncethe bagger 181 is positioned in the track, it can be docked using, forexample, hand crank 472. After docking, down clamps (not shown) can beused to hold bagger 181 to the track to, for example, minimizevibration. A limit switch (not shown) can optionally be used inconjunction with docking so that when bagger 181 is undocked, bagger 181stops operation.

FIGS. 9A, 9B and 9C, taken together, is an exemplary embodiment of aflow chart of a method of operation of the bagger. At step 902, system100, ALPS 250 and/or bagger 181 is initialized for operation.Initialization can include, for example, power up and diagnostic checks.

At step 904, the next literature pack label(s) and/or pharmaceuticalcontainer labels are scanned. If, at step 908, it is determined thatthere is a mismatch between, for example, a literature pack label and apharmaceutical container label, then the order can be manually processedat manual packing station 137 and/or placed on tote conveyor 1521 (FIG.2B), which can transfer any bottles to an operator who can manually fillthe order. If at step 908 it is determined that matching literature packand pharmaceutical container labels exist, then a bag 83 can be fedthrough bagger 181 at step 910. Printer 260 can print a bag 83 labelcorresponding to the prescription order.

The printed bag 83 label can be scanned by scanner (not shown)positioned downstream of printer 260 to determine of the label isaccurate and corresponds to the prescription order. If the label is notaccurate, another label can be printed at step 912. If the label isaccurate, the label can be applied to bag 83 by tamp 255.

At step 918, the bag position can be determined by indexing. Forexample, a perforation between bags can be read by a scanner todetermine the location of the bag. After indexing, the bag 83 isforwarded to an open position, where jaw 451 and fingers 608 a, 608 bcan open the bag 83.

At step 922, any literature associated with the prescription order, andany pharmaceutical containers associated with the prescription order areinserted into bag 83. At step 924, seal bar assembly 240 can be used toseal the bag 83.

At step 926, index rolls 7 a, 7 b (FIG. 7A) can be used to retract bag83 (in the direction of arrow 468, FIG. 4A) and/or to break the bag 83along a perforation. The index rolls 7 a, 7 b can be driven by, forexample, a servo motor 455. At decision step 928, a determination ismade whether another bag needs to be supplied for a next prescriptionorder. If so, the method resumes at step 904. If no more prescriptionorders are to be processed, then the process ends. The above stepsand/or sequence of steps may be modified as well, in accordance with theprocesses described herein.

In general, it should be emphasized that the various components ofembodiments of the present invention can be implemented in hardware,software or a combination thereof. In such embodiments, the variouscomponents and steps would be implemented in hardware and/or software toperform the functions of embodiments of the present invention. Anypresently available or future developed computer software languageand/or hardware components can be employed in such embodiments of thepresent invention. For example, at least some of the functionalitymentioned above could be implemented using Visual Basic, C, C++, or anyassembly language appropriate in view of the processor(s) being used. Itcould also be written in an interpretive environment such as Java andtransported to multiple destinations to various users.

The many features and advantages of embodiments of the present inventionare apparent from the detailed specification, and thus, it is intendedby the appended claims to cover all such features and advantages of theinvention which fall within the true spirit and scope of the invention.Further, since numerous modifications and variations will readily occurto those skilled in the art, it is not desired to limit the invention tothe exact construction and operation illustrated and described, andaccordingly, all suitable modifications and equivalents may be resortedto, falling within the scope of the invention.

1. A method for filling a plurality of prescription orders, comprisingthe steps of: transporting in at least a first direction a plurality ofcontainers by a first plurality of rollers; transporting in the firstdirection a plurality of labels by a second plurality of rollers,optionally disposed on a backing sheet; printing on a label for at leastone of the plurality of containers, the name and address information ofa recipient of a prescription order; securely placing a label on the atleast one of the plurality of containers, one container at a time, whenthe at least one of the plurality of containers reach a predeterminedposition; opening the at least one of the plurality of containers; andplacing in the opened at least one of the plurality of containers apharmaceutical container with enclosed medication, corresponding to theprescription order associated with the label, and sending the at leastone of the plurality of containers with the medication to the recipientof the prescription.
 2. The method according to claim 1, furthercomprising the step of discarding a container that cannot be opened. 3.The method according to claim 1, further comprising the step of placinga literature pack in the opened container.
 4. The method according toclaim 3, further comprising the step of sealing the opened container. 5.The method according to claim 4, further comprising the step oftransporting the at least one of the plurality of containers in at leasta second direction subsequent to sealing the container.
 6. The methodaccording to claim 1, further comprising the step of sealing the openedcontainer.
 7. The method according to claim 1, further comprising thestep of conveying the plurality of containers a predetermined amount inthe at least first direction to a position where the container isopened.
 8. The method according to claim 7, further comprising the stepof sensing whether the at least one of the plurality of containers is inposition for opening.
 9. The method according to claim 1, furthercomprising the step sensing whether the at least one of the containersis in position for opening.
 10. The method according to claim 1, furthercomprising the step of separating the label from the backing sheet priorto said placing step.
 11. The method according to claim 10, furthercomprising the step of providing a vacuum to hold the label in placeprior to placing the label on the at least one of the plurality ofcontainers.
 12. The method according to claim 1, further comprising thestep of providing a vacuum to hold the label in place prior to placingthe label on at least one of the plurality of containers.
 13. The methodaccording to claim 1, further comprising the step of placing the labelon a first one of the plurality of containers substantiallysimultaneously while opening a second one of the plurality of containershaving another label placed thereon.
 14. The method according to claim1, wherein at least one of the first plurality of rollers and secondplurality of rollers rotate in concert in the first direction to conveyat least one of the plurality of containers and plurality of labels. 15.The method according to claim 1, wherein the first plurality of rollersdefine an area through which the containers are conveyed.
 16. The methodaccording to claim 1, wherein the second plurality of rollers define anarea through which the plurality of labels and the backing material areconveyed.
 17. A method for filling a plurality of prescription orders,comprising the steps of: transporting in at least a first direction aplurality of containers by a first plurality of rollers; transporting inthe first direction a plurality of labels by a second plurality ofrollers, optionally disposed on a backing sheet; printing on a label forat least one of the plurality of containers, information correspondingto a recipient of a prescription order; securely placing a label on theat least one of the plurality of containers, one container at a time,when the at least one of the plurality of containers reach apredetermined position; opening the at least one of the plurality ofcontainers; and placing in the opened at least one of the plurality ofcontainers a pharmaceutical container with enclosed medication,corresponding to the prescription order associated with the label, andsending the at least one of the plurality of containers with themedication to the recipient of the prescription.
 18. The methodaccording to claim 17, further comprising the step of discarding acontainer that cannot be opened.
 19. The method according to claim 17,further comprising the step of placing a literature pack in the openedcontainer.
 20. The method according to claim 17, further comprising thestep of conveying the plurality of containers a predetermined amount inthe at least first direction to a position where the container isopened.
 21. The method according to claim 20, further comprising thestep of sensing whether the at least one of the plurality of containersis in position for opening.
 22. The method according to claim 17,further comprising the step sensing whether the at least one of thecontainers is in position for opening.
 23. The method according to claim17, further comprising the step of transporting the at least one of theplurality of containers in at least a second direction subsequent tosealing the container.
 24. The method according to claim 17, furthercomprising the steps of separating the label from the backing sheetprior to said placing step, and providing a vacuum to hold the label inplace prior to placing the label on the at least one of the plurality ofcontainers.
 25. The method according to claim 17, further comprising thestep of placing the label on a first one of the plurality of containerssubstantially simultaneously while opening a second one of the pluralityof containers having another label placed thereon.
 26. The methodaccording to claim 17, wherein at least one of the first plurality ofrollers and second plurality of rollers rotate in concert in the firstdirection to convey at least one of the plurality of containers andplurality of labels.
 27. The method according to claim 17, wherein thefirst plurality of rollers define an area through which the containersare conveyed.
 28. The method according to claim 17, wherein the secondplurality of rollers define an area through which the plurality oflabels and the backing material are conveyed.